ONSTRUCTION NGINEERING ERVICES PROJECT … Number: IM 15-1(109)0 & ... Constructability...
Transcript of ONSTRUCTION NGINEERING ERVICES PROJECT … Number: IM 15-1(109)0 & ... Constructability...
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CONSTRUCTION ENGINEERING SERVICES
PROJECT REVIEW REPORT
Project Number: IM 15-1(109)0 & IM 15-1(107)0
Letting Date: August 26, 2010
Project Description: Monida-Lima (SB) & Monida-Lima (NB)
MDT District: Butte
Control Number: 6921 & 6923 EPM: John Starcevich
Review Date: August 11 & September 15, 21, & 27 , 2011
Reviewed By: Mark Snow In Company With: N/A
Project Description: Cold milling, PMS overlay, guardrail, seal and cover and pavement markings on the Monida – Lima (SB) & (NB) projects located in Beaverhead County.
Review Type: Constructability Investigatory Oversight
Post Construction
Subject Specific- Warm Plant Mix Bituminous Surfacing Paving (3/4 inch Grade “S” Volumetric)
Training
CONTRACT INFORMATION
Contractor: Jim Gilman Excavating Inc.
Contract Amount: $9,367,205.26
Contract Payments To-Date $4,389,276.94 (Estimate #5)
Contract Time/Completion Date: 110 Working Days
Contract Time Used to-Date: 107 Working Days (9/30/11)
Letting Date: August 26, 2010
Award Date: September 7, 2010
Notice to Proceed Date: May 6, 2011
Date Work Began: May 6, 2011
Work In Progress: Plant Mix Bituminous Surfacing (Control) and Warm Mix Bituminous
Surfacing Paving (19.0mm Grade “S” Volumetric)
19.0mm Gr. “S” Plant Mix Bituminous Surfacing for the Monida-Lima (SB) & (NB)
projects was produced using a Gencor/Barber Greene Ultra 400 counter flow drum dryer. This
plant is rated at 500 tons per hour. The Air Quality certification was updated in May 21, 2009.
Air Quality recertification will be required in 2013. All weight equipment was certified on
August 12, 2011 and the Certification documentation was available for inspection in the control
house. The location of plant mix production is as follows: SW ¼ SW ¼ SE ¼ SW ¼, Section
17, Township 14 South, Range 7 West.
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Gencor Ultra 400 Counter Flow Drum Dryer
19mm Grade “S” Control and Warm Mix Bituminous Surfacing Production:
19.0 mm Grade “S” Control and Warm Mix Bituminous Surfacing were produced at an
average rate of 400 tons per hour. Production commenced using mix design bin split values of
46.36% coarse, 7.89% intermediate, 44.38% crushed fines, and 1.38% hydrated lime. The start-
up asphalt binder plant setting was adjusted from the mix design target of 4.6% to a plant setting
of 4.55%. Spot checks averaged 4.58% through thirty eight (38) days of production. Mix
moisture averaged 0.05% with 3.0% stockpile moisture entered into the plant. The above
mentioned bin split values and asphalt binder setting remained constant throughout production of
control and Warm Mix bituminous surfacing production. The average discharge temperature for
control plant mix surfacing was 320 degrees Fahrenheit. Sasobit Warm Mix and the foamed
Warm Mix average discharge temperatures were 285 degrees Fahrenheit. Evotherm Warm Mix
average discharge temperature was 274 degrees Fahrenheit.
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Three Warm Mix test sections were placed on the Monida Lima south bound project. A
description of the additives and processes used to produce the Warm Mix product is as follows.
The following description of Sasobit was acquired from the product brochure supplied by
Sasol Wax North America Corporation. “Sasobit is a crystalline, long chain aliphatic
polymethylene hydrocarbon produced from natural gas using the Fischer-Tropsch (FT) process.
The unique properties of Sasobit are high melting point, low melt viscosity and high crystallinity
(hardness). These properties are used to great effect to modify the asphalt binder. The chemical
structure of Sasobit is identical to paraffin waxes that are found in crude oil, except that it has a
higher molecular weight. Therefore, it dissolves easily into asphalt at temperatures above 248
degrees Fahrenheit and will not separate out in storage. When Sasobit is added to softer grades of
asphalt binder, there is no bleeding that is associated with low molecular weight waxes. This
provides the possibility to upgrade softer grades of asphalt. Sasobit is used as a flow improver,
both during the asphalt mixing process and during laydown operations. The dramatic reduction
in viscosity obtained by adding Sasobit to asphalt at working temperatures makes the asphalt
easier to process, providing the option of reducing the working/mixing temperatures and thereby
reducing fume emissions and decreases production costs associated higher mixing and
compaction temperatures. Sasobit’s high crystallinity and hardness are used to modify asphalt
binders to produce rut resistant plant mix pavements. It offers an alternative to asphalt polymer
modification when increased stiffness is required to prevent rutting. Sasobit can be added in
combination with polymer modified asphalts to produce a binder that exhibits stiff qualities, but
also offer some of the elastic benefits of polymer modification. Sasobit can be blown into the
plant drum near the point of asphalt binder introduction,” however on this particular project this
additive was blended into the binder at the Idaho Asphalt refinery. “The same procedures used to
blend polymers in asphalt binder work when blending Sasobit into the binder. The addition can
run concurrently with the polymer modification. Sasobit will aid in the dispersion of the polymer
and will decrease the reaction time needed to digest the polymer. Sasobit is safe and easy to
handle. It can be used in food-grade applications such as adhesives and therefore holds no health
hazards for workers.”
The following description of EvothermTM was acquired from the product brochure
supplied by MeadWestvaco Asphalt Innovations. “EvothermTM DAT (Dispersed Asphalt
Technology) is a chemical additive that is injected into the asphalt binder feed line just prior to
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the asphalts introduction into the mixing chamber. The EvothermTM DAT Warm Mix method
chemically decreases the viscosity of the asphalt binder and adds a small amount of water to the
hot asphalt binder flow, which improves coating of the plant mix aggregate and workability of
the produced product. By lowering plant mix production and placement temperatures, the jobsite
becomes a more comfortable odor-free working environment. Contractors using EvothermTM
have reported increased worker productivity and decreased worked fatigue. Paving with low
temperature EvothermTM technology eliminates the emissions for which asphalt paving is most
scrutinized. Mixes made with EvothermTM consistently achieve roadway densities easier than
conventional hot plant paving mixtures. Even difficult to compact materials such as polymer
modified asphalts and coarse mixes are easier to compact at lower temperatures. The temperature
of EvothermTM mixes is much closer to ambient temperatures than conventional hot mix
products, so low temperature mixes do not lose energy as quickly. A reduced rate of heat loss,
combined with improved compaction, makes EvothermTM an effective solution to cooler
temperature paving and longer hauls, effectively extending the paving season and the radius of
operation for mix plants.”
The following description of Aesco/Madsen Eco - foam – II foaming Warm Mix method
was acquired from the product brochure supplied by Aesco/Madsen Corporation. “With this
method pressurized water is injected into the asphalt binder flow just prior to its introduction into
the mixing chamber. The Aesco/Madsen’s static inline vortex mixer, known as Eco – foam II, is
a motionless static mixer in which fluids are injected and rapidly mixed by a combination of
alternate vortex shedding and shear – induced turbulence, which produces superior fluid mixing.
The unmixed asphalt flows to the static mixer and is forced through the mixer restriction to form
a high speed flow. The water/additive is injected into the low – speed reversed flow region
downstream of the mixing tabs. This effectively speeds the mixing of the asphalt and the low –
speed water/additive. The Aesco/Madsen’s static inline vortex mixer makes use of shear zone
turbulence. With a unique orifice plate design, this mixer causes great turbulence that also
enhances the mixing process. Vortex shedding happens when a fluid passes an object, or
obstruction, and an oscillation occurs. The oscillation, or swirls, downstream create alternating
low – pressure zones, which also help in the mixing process. The dominant feature of the
Aesco/Madsen’s static inline vortex mixer is the production of two very strong jets emanating
from the open area in the cut – out plate. Velocities in the cores of these jets reach five times that
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of the upstream asphalt flow. Large reverse flow regions surround these jets and very high
amplitude shear layers exist in between the jet and the reverse flow. The effective area where
high shear layers exist is largely due to the dual jet structure and the non – circular nature of the
plate cut – outs. Injecting water directly into the center of the liquid asphalt causes the water to
instantly turn to steam in the form of small bubbles. When combined with the hot asphalt, the
result is a foamed asphalt mixture. This foamed asphalt temporarily reduces the viscosity of the
asphalt during the mixing process this allows the aggregate in the dryer to efficiently coat at
temperatures that in some cases 50 – 60 degrees Fahrenheit lower than normal plant mix. This
results in asphalt mix temperatures at the discharge of the mixer in the 240 – 290 degree
Fahrenheit range, while still maintaining good workability during the laydown process.” Another
advantage of this system is that water or additive can be injected with this equipment. On this
project EvothermTM DAT and water for the foamed Warm Mix product were injected using the
Aesco/Madsen’s static inline vortex mixing system.
Aesco/Madsen’s Eco – Foam II Static Inline Vortex Mixer Prior to Installation
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Aesco/Madsen’s Eco – Foam II Static Inline Vortex Mixer after Installation
Control House Installed Digital Flow Rate Controller
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Water/Additive Injection Pump and Water Storage Tank
19mm Grade “S” Control and Warm Mix Bituminous Surfacing Placement:
19mm Grade “S” Plant Mix Bituminous Surfacing was placed using a Volvo PF 6170
paver with a Cedarapids MS - 2 pickup machine. Compaction on the top lift placed at the time of
my visit was performed using one (1) Caterpillar CB64, one (1) Ingersoll Rand DD – 158, one
(1) Ingersoll Rand DD – 130HF and one (1) Hamm HD+140. All four rollers were dual steel
drum vibratory rollers. The Caterpillar CB – 634D and Ingersoll Rand DD – 158 worked in
tandem providing break down, with the Ingersoll Rand DD – 158 working intermediate
compaction. Finish rolling to remove any remaining surface irregularities was completed using
the Hamm HD+140. Placement commenced at project stationing 2887+81, in the north bound
passing lane.
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Volvo PF 6170 Paver and Cedarapids MS – 2 Pickup Machine
Ingersoll Rand DD – 130 HF, Ingersoll Rand DD – 158 & Caterpillar CB64 Rollers
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Quality Control (QC) Conducted by the Contractor:
The contractor did not have an employee/consultant on the site to run sieve analysis or to
perform plant mix volumetric testing. Density testing to control plant mix compaction was
performed by an employee of Jim Gilman Excavation Inc. using a Seaman C – 300 Density
Gauge.
Jim Gilman Excavating Inc. C – 300 Seaman Density Gauge
Quality Assurance (QA) Testing:
The Project Quality Assurance (QA) acceptance samples were acquired at the plant in
accordance with standard specification MT – 303. Quality Assurance testing at the time of my
visit was performed by MDT WAQTC certified technicians and was in accordance with
specified test methods. All Quality Assurance samples for Control and Warm Mix acceptance
were fabricated and tested in a timely manner by Butte District Materials Laboratory personnel.
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(Control) Consultant Design, Helena Verification
And Field Evaluated Volumetric Comparison Data:
VMA VFA VTM D/A Rice
*Consultant 13.0 73.8 3.5 1.4 2.458
Helena Lab 13.6 64.8 4.8 1.5 2.459
** Field Lab 12.8 78.0 2.9 1.7 2.455
*** Field Lab 13.2 76.0 3.2 1.6 2.454
**** Prelim. Targets 13.6 76.0 3.4 1.6
* Consultant mix design by HKM Engineering Inc.
** Avg. of four (4) field run courtesy samples.
*** Avg. of sixty (60) field run Quality Assurance control samples.
*** Sasobit preliminary targets set at 3000 tons.
(Sasobit Warm Mix) Consultant Design, Helena Verification
And Field Evaluated Volumetric Comparison Data:
VMA VFA VTM D/A Rice
*Consultant 13.0 73.8 3.5 1.4 2.458
Helena Lab 13.6 66.4 4.6 1.5 2.454
** Field Lab 13.2 71.0 3.8 1.6 2.463
*** Field Lab 12.9 73.2 3.5 1.6 2.463
**** Prelim. Targets 13.2 71.0 3.8 1.5
* Consultant mix design by HKM Engineering Inc.
** Avg. of four (4) field run courtesy samples.
*** Avg. of eleven (11) field run Quality Assurance Sasobit samples.
*** Control preliminary targets set at 3000 tons.
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(EvothermTM
Warm Mix) Consultant Design, Helena Verification
And Field Evaluated Volumetric Comparison Data:
VMA VFA VTM D/A Rice
*Consultant 13.0 73.8 3.5 1.4 2.458
Helena Lab 12.6 73.2 3.4 1.5 2.452
** Field Lab 13.0 76.0 3.2 1.5 2.456
*** Field Lab 13.1 75.2 3.3 1.5 2.456
**** Prelim. Targets 13.0 75.0 3.4 1.6
* Consultant mix design by HKM Engineering Inc.
** Avg. of two (2) field run courtesy samples.
*** Avg. of ten (10) field run Quality Assurance EvothermTM samples.
*** Control preliminary targets set at 2500 tons.
(Foamed Warm Mix) Consultant Design, Helena Verification
And Field Evaluated Volumetric Comparison Data:
VMA VFA VTM D/A Rice
*Consultant 13.0 73.8 3.5 1.4 2.458
Helena Lab 13.6 64.8 4.8 1.5 2.459
** Field Lab 12.9 78.0 2.9 1.6 2.452
*** Field Lab 12.9 76.3 3.1 1.5 2.456
**** Prelim. Targets 13.0 75.0 3.4 1.5
* Consultant mix design by HKM Engineering Inc.
** Avg. of two (2) field run courtesy samples.
*** Avg. of ten (10) field run Quality Assurance control samples.
*** Control preliminary targets set at 2600 tons.
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Hamburg Wheel Track Testing:
Control Hamburg Wheel Track samples were submitted for analysis on August 13, 2011.
At 15,000 passes the results averaged 3.2mm of specimen surface deformation from the Helena
Materials Laboratory analysis. The Helena Materials Laboratory Hamburg Wheel Track analysis
at the time of mix design verification averaged 6.8mm at 20,000 passes.
Sasobit Warm Mix Hamburg Wheel Track samples were submitted for analysis on
September 15, 2011. At 15,000 passes the results averaged 1.6mm of specimen surface
deformation from the Helena Materials Laboratory analysis. The Helena Materials Laboratory
Hamburg Wheel Track analysis at the time of mix design verification averaged 6.5mm at 20,000
passes.
EvothermTM Warm Mix Hamburg Wheel Track samples were submitted for analysis on
September 21, 2011. At 15,000 passes the results averaged 2.0mm of specimen surface
deformation from the Helena Materials Laboratory analysis. The Helena Materials Laboratory
Hamburg Wheel Track analysis at the time of mix design verification averaged 7.8mm at 20,000
passes.
Foamed Warm Mix Hamburg Wheel Track samples were submitted for analysis on
September 27, 2010. The results for these samples were unavailable at the time of this report.
The Helena Materials Laboratory Hamburg Wheel Track analysis at the time of mix design
verification averaged 6.8mm at 20,000 passes.
Quality Assurance Density Testing:
Quality Assurance density testing was performed to obtain percent compaction on cores
taken randomly from the roadway. Through twenty one (21) lots of Control Quality Assurance
density tests, the density average was 94.6%. Eleven (11) of these twenty one (21) lots had
calculated Quality Assurance density incentive. There were no disincentive/deduct lots
associated with control plant mix placement. The average of five (5) Sasobit Warm Mix Quality
Assurance density lots was 94.0%. Two (2) of the five (5) lots had calculated Quality Assurance
density incentive. One (1) of the five (5) lots had calculated Quality Assurance density
disincentive/deduct. The density average (Xn) of this deduct lot was 93.6%. The average of four
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(4) EvothermTM Warm Mix Quality Assurance density lots was 94.5%. Three (3) of the four (4)
lots had calculated Quality Assurance density incentive. There were no disincentive/deduct lots
associated with EvothermTM Warm Mix placement. The average of three (3) Foamed Warm Mix
Quality Assurance density lots was 94.5%. None of the three (3) Foamed Warm Mix density lots
had calculated Quality Assurance density incentive or disincentive.
Troxler NTO Asphalt Content Ignition Oven Data:
The ignition burn oven scale verification was 0.014% at 5000 grams which is acceptable
being less than 0.025% according to manufacturer’s recommendations. The average of ninety
one (91) field production burns was 4.66%. Spot checks averaged 4.58% through thirty eight
(38) days of production. Mix design target asphalt binder content was 4.6% Idaho Asphalt P.G.
70 -28. The average 200 mesh percentage from the field burn sieve analyses was 7.3%. Mix
design target results for the 200 mesh were noted at 5.8%.
Federal Highway Administration Research Testing:
The Federal Highway Administration (FHWA) mobile research testing facility was
moved to the “Monida – Lima NB & SB” project site near Lima, Montana from a high RAP
(40%) research project located near Tilton, New Hampshire. The trip covered approximately
2500 miles. At the Monida project site samples of control and warm mix were evaluated for
volumetric properties, void distribution, bulk gravity, maximum specific gravity, ignition burn
asphalt content, moisture content, fine aggregate angularity, coarse aggregate angularity, particle
coating, and aggregate sieve analysis. FHWA s’ personnel obtained and fabricated additional
gyratory samples of control and Warm Mix surfacing for future off-site research testing. Other
samples obtained for off-site research testing included samples of P.G. asphalt binder, hydrated
lime, aggregate and non-compacted control and Warm Mix surfacing. The off-site research
testing will be conducted at the FHWA s’ research center located in Washington, DC and at the
Texas Transportation Institute located on the A & M University campus in Austin Texas. Some
of the off-site testing will include Hamburg wheel track rut testing, tensile strength ratio testing,
G-star P.G. asphalt binder testing, extracted binder content and sieve analysis.
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Federal Highway Administration’s (FHWA) Mobile Field Testing Facility (External View)
FHWA’s Mobile Field Testing Facility (Internal View))
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FHWAs’ IPC Servopac and Pine Field Gyratory Compactors
FHWAs’ Maximum Specific Gravity (Rice Gravity) Testing Equipment
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FHWAs’ Field Laboratory Personnel Sampling (Control) Plant Mix Surfacing
A Portion of FHWAs’ Field Gyratory Compacted Specimens (for off-site testing)
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In the pictures above Federal Highway Administration (FHWA) mobile research testing
facility is shown in external and internal views, the two gyratory compactors used for field
specimen fabrication, maximum specific gravity testing equipment, FHWAs’ staff obtaining
five-gallon buckets of the control plant mix product and a portion of the field gyratory specimens
compacted for off-site testing.
Washington State University Research Sampling:
Representatives of Washington State University were also on-site to collect samples for
future off-site research testing. Samples acquired included compacted gyratory specimens,
roadway drilled cores, P.G. asphalt binder, hydrated lime, aggregate and non-compacted control
and Warm Mix surfacing. Gyratory compacted specimens were fabricated for the Washington
State University representatives by Montana Department of Transportation Butte District
Materials Laboratory personnel and FHWA field research staff. Roadway drilled cores were
provided Montana Department of Transportation Butte District Materials Laboratory personnel.
This reviewer would like to extend a special “thank you” to the Butte District Materials
Laboratory personnel and the FHWA field research staff for the extra effort involved in the
fabrication of gyratory specimens and acquiring core drilled roadway samples.
Issues Discussed & Resolved:
� No issues were noted at the time of my visit
Questions from E.P.M. and Staff:
� A member of the field construction staff asked. “What is the proper protocol to be
followed when setting the field target density?” The proper procedure is outlined in
Materials Manual section Mt 328 sub section 3.3 & 3.4, as noted below.
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3.3 “When two (2) field maximum specific gravities have been determined using MT
321, average the results. Use the average for the field target density. This target will be effective
retroactive to the start of plant mix production on the project.”
3.4 “When four (4) field rice gravities are completed, average the four test values. If a
change of 0.5 pounds per cubic foot (8.0 kg per cubic meter) or greater is calculated change to
the new average density. This change will become effective at the time the last sample was
obtained.”
Daily Maintenance Practices in MDT Field Testing Facilities:
The field testing trailer was found in a clean condition with all pertinent equipment in
working order. The lead technician informed this reviewer that the volumetric flask used in
determining maximum specific gravity (Rice Gravity) was calibrated daily. The Gyratory
compactor was greased daily or as needed, depending on the number of specimens compacted.
Molds, splitting pans, spatulas & various tool used in the testing procedure were cleaned after
every test.
Dynamic Angle Validation (DAV) Internal Angle Results:
A check was performed on the internal angle of Pine Instrument Company model
AFGB1A Gyratory compactor serial number 5263 which was being used for Quality Assurance
specimen fabrication. The calibration sticker attached to this machine was dated December 9,
2010. The measured average internal angle from the calibration certificate was 1.156 degrees. A
field check was accomplished using DAV model number DAV-1, serial number 132. The
resulting angle was 1.161 degrees which is within the specified range of 1.140 to 1.180 degrees.